Stall enclosure



Oct. 30, 1962 G. D. SWAN 3,060,453

I STALL ENCLOSURE Filed Dec. 18, 1959 3 Sheets-Sheet 1 F/6./ FIG. 3 I

// 20 4,5 l INVENTOR.

F/@ 2 /2 650/?65 DEV/E) SWAN Oct. 30, 1962 e. D. SWAN 3,060,453

STALL ENCLOSURE Filed Dec. 18, 1959 3 Sheets-Sheet 2 ATTORNEY 1962 G. D.SWAN 3,060,453

STALL ENCLOSURE Filed Dec. 18, 1959 3 Sheets-Sheet 3 FIG. 8

i: f 1; v F/6., 9 34/ ll INVENTbR.

United States This invention relates to a structurally and functionallyimproved stall enclosure, and in its preferred aspects aims to providesuch an enclosure for use as a shower stall.

It is a primary object of the invention to furnish a unit of thischaracter which will not require any door or curtain at its portal orentrance, and in which no splash or spray generated by the shower headwill cause water to flow outwardly through that portal.

A further object is that of designing a unit of this type which may beeconomically manufactured, either directly at the locale of installationor otherwise. Where manufactured at a relatively distant location, theseveral parts providing the enclosure may be produced in quantity andreadily stored in compact organizations for ship ping or other purposes.

In any event, by means of the present teachings, an assembly is providedwhich will include only a few parts, capable of being readily coupled toeach other to furnish a leakproof stall functioning with freedom fromall difiiculties for indefinite periods of time. Moreover, the parts maybe combined in various manners by relatively unskilled labor to furnishdesired layouts compatible with the design of any given building andspace capable of accommodating the stall.

A still further object is that of teaching an improved method ofmanufacture whereby one or more of the components of the stall enclosuremay be provided. However, those units may be otherwise manufactured.Also, the herein-described method may be advantageously employed tofurnish desired sheets of material for other units.

With these and other objects in mind, reference is bad to the attachedsheets of drawings illustrating one practical embodiment of theinvention, and in which:

FIG. 1 is a fragmentary front elevation of the entrance or portalportion of the enclosure;

FIG. 2 is a sectional plan view thereof;

FIG. 3 is a transverse sectional view taken along the line 3-3 in thedirection of the arrows, as indicated in FIG. 2;

FIGS. 4 and 5 are sectional side views taken along the line 4--4 and 5-5in the direction of the arrows, as indicated in FIG. 2, 'and showing thepreferred roof and base sections of the stall;

FIG. 6 is an exploded perspective view of the preferred components whichprovide the enclosure;

FIG. 7 is a fragmentary enlarged sectional View of a detail of theassembly involving the side wall and pan portions thereof; and 1 FIGS. 8and 9 are fragmentary sectional views, inenlarged scale, illustrative ofthe procedure to be followed in conforming to the improved method.

It is to be understood that an enclosure embodying the present teachingsis primarily intended to be in cluded within a housing structure whichwill ordinarily embrace an adjoining room. It may, of course, form aseparate unit. In any event, vertically extending supporting members 10are included in thestructure, and certain of these are spaced a distanceequal to that which is to define the width of the portal or entranceportion of the stall. A facing sheet or wall structure 11 may intervenethese members and may also mount a frame 12 of suitable outline todefine the entrance. Additionally, there will normally be included inthe structure a floor 13 of any desired material mounted upon supportingbeams 14. The stall itself will include a side wall supported upon a panbase and preferably covered by a ceiling part, as hereinafter describedin detail. These units will extend adjacent and be braced in anysuitable manner by the supporting structure of the housing, andespecially vertical members such as 10, the wall section 11 and whereotherwise necessary. Such bracing has not been shown in detail in thepresent illustrations. As has been shown, however, the pan will restupon the floor section 13 or its equivalent.

Considering the side wall of the stall, it will include a Sheet ofmaterial having an outer end portion 15 which is continued in the formof a spiral or volute shape, as indicated at 16, throughout the greaterpart of a circle. The sheet is continued in the form of afitting-mounting face 17, in turn continued in a reversely curvedsurface 18 terminating in a face 19 extending substantially parallel toand spaced from surface 15. The outer edge zones of surfaces 15 and 19terminate in a jamb embracing angularly extending flange portions 2t).The spacing between surfaces 15 and 19 is adequate to furnish a portalor entrance portion. Surface 17 has an area such that it may supportwithout difiiculty fittings such as valve handles 21 and 'a shower head22. Other fittings may also, if desired, be thus supported.

In the latter connection it will be observed, as indicated by the dottedlines 23, a further and relatively low wall may intervene spaced zonesof the sheet providing surfaces 15 and 19, to define a tub. By havingthis wall extend at elected angles, the area of the tub may be increasedor diminished at will. Of course, a separate tub may be positionedwithin the stall; the side wall of the latter being contiguous andsuitably joined to the faces of the tub in any acceptable mannerNormally, however, the stall will include merely a shower head fittingand the valves controlling the flow of water. As illustrated especiallyin FIG. 2, face or baflle surface 17 extends outwardly from the axisdefined by surfaces 18 and 19 at an angle of approximately 45". In anyevent, the sheet furnishing the side wall extends throughoutsubstantially one convolution.

Where a tub is present the rim of the same will act as a splash guard,such that the angle of mounting face 17 may be decreased. Thisangularity may be diminished to a point where it is just slightly inexcess of Where no tub or other splash guard is present, the angularityof face 17 should not be less than substantially In all events, thefitting-mounting face or baffle 17 should be located at a pointapproximately midway between face 15 and the opposite inner end wall ofthe stall. If the tub rim extends as shown in FIG. 2, a second drainopening may be provided between the rim and the sill or curb of the panbase.

Considering the pan base, it will preferably include a deck or lowersurface 24-. The outline of the latter will conform to the normaloutline of the side wall. However, the area of that base will beslightly less than that defined by the side wall. This will be true whenthe latter is unrestrained and simply placed on a horizontal supportingsurface. Otherwise, the normal outline f the side wall and base are intheir main parts identical. Extending upwardly from the deck 24- andintegral therewith is a side wall 25. Intermediate its upper and loweredges, this wall is flanged outwardly, as at 26', to provide a sheetsupporting or ledge surface. The end zones of this wall extend parallelto each other and are joined by a sill or curb 26 providing a connectingstructure formed with shoulders 27 in line with the ledge 26. As shownespecially in 'FIG. 7, a grid pattern. may extend outwardly from thelower face of deck 24; a portion of that pattern having been indicatedat 28. By such an expedient, the base pan is suitably rigidified.

The ceiling of the stall may be furnished by a nit generally indicatedat 29, the parts of which are ge erally a mere reversal of thoseproviding the base pan- Flange portions 20 are preferably continued, asindicated at 30 and 31, to furnish contact portions or face platesbearing against the shoulders of surfaces 27. As will be noted, theinner vertical walls of those shoulders are spaced from thecorresponding faces of wall 25 to furnish openings such that theadjacent edge zones of the main side wall may pass therethrough toaccordingly furnish an interlocking structure. Conveniently aftermanufacture, deck surface 24 may be formed with an opening 32accommodating a drain pipe 33. Similarly, the ceiling section 29 may beformed with such an opening, which in that instance conveniently servesto accommodate a lighting fixture (not shown). Shoulder 27 forms a faceplate to receive horizontal flanges 31. Wall section 25 terminates atsill 26, so that when the parts are in posit-ion, a locked joint isprovided.

As particularly hown in FIGS. 4 and 5, the main housing structure mayinclude horizontally extending structural parts 33. These will extendrespectively into the sections 26 of the ceiling part and the base pan,to suitably rigidify them. The sheet forming the main side wall, inaddition to being supported by joists or similar units, will berigidifled by the frame 12. To achive this, and as shown in FIG. 2,flange portions 20 may be interposed between that frame and the adjacentsurface of wall 11.

The materials providing the units of the stall or enclosure are formedof sprayed resins reinforced by Fiberglas. These resins, according tothe preferred concept of this invention, will be of the type which willset at room temperatures. Inexpensive forms or patterns for theproduction of theparts may be made of any number of materials, such asordinary wood, plywood, composition materials, etc. Styrene isespecially useful in the providing of patterns, in that its surface isfree of pits and irregularities.

ere the assembly is produced at a manufacturing plant, pressure moldingwill preferably be used. Otherwise, a spray gun will be used for thedistribution of the desired resin material, and will shred the ropelikefibers of Fiberglas. These resins are mixed with any desired colors andthe required catalyst in One continuous operation. The wall castingproduced according to any procedure will be designed to sweep in a widerare than that of the base or ceiling. This will create a springlikeaction when the Wall unit is fitted onto the adjacent base and ceilingparts, if the latter is used.

In thi connection, it will be understood that the ceiling may, ofcourse, be separately formed to include a decorative surface, atransparent or translucent member, or otherwise. In any event, thespring action due to the inherent memory of the plastic employed exertssufficient pressure along the curved flange or ledge of the base castingto hold the wall in place. This may be achieved without the use offasteners or adhesives, although desired materials may, of course, beemployed. The open form of the wall casting permits nesting of a numberof these units, thus minimizing problems ordinarily arising in storageor shipment. Also, it facilitates handling at a job site, where buildingequipment must necessarily pass through normal openings. The base andceiling units being identical except for reversal of pattern, provide,in conjunction with the side wall, a monolithic structure. Theoverlapping of the base and side wall unit forms a locked joint. Similarjoining of the ceiling casting assures structural solidity andstability. The amalgamated whole is comparable to a capsule includingtop and bottom caps. By upending the assembly, a reversal of the unit isfeasible, so that flexibility of the finished plan is possible withoutresorting to separate and special castings.

As afore brought cut, surface 17 extends at a 45 angle with the axis ofthe opening or portal. By having the parts thus disposed, it becomespractically impossible to splash water through that opening. When thejamb is fastened as described, its hooklike edge zones form an anchorfor the main spring action of the wall section. With a ceiling unitbeing employed, both the upper and lower ends of the portal surfaces areanchored to maintain stability and proper configuration of the entrance.

A preferred method of forming parts of the enclosure has beendiagrammatically illustrated in FIGS. 8 and 9. That method may, however,be employed to advantage in the manufacture of articles other than oneor more of the components providing the stall.

Thus, as shown in these figures, the numeral 34 indicates the mold,conveniently formed of plywood, styrene, Fiberglas, metal or othersuitable materials, and the surface of which should have a fine orpolished finish. If necessary, that surface may be coated with aresin-base lacquer 35 and a superimposed layer 36 of mold-releasematerial. The latter may be wax, Teflon, silicone, etc. T hereupon, alayer 37 of a resin which sets at room temperature is applied. Thatresin may be a suitable epoxy, polyester or vinyl. While this layer isstill somewhat adhesive, fine particles 38 are embedded therein. Theseparticles may be glass or stainless steel beads, marble, Carborundum,granite, etc. A flock gun may be employed to distribute them. In thecase of glass beads, they may be approximately .003" in diameter. In anyevent, they should be disposed with their edges touching each other. Amat 49 of woven Fiberglas may be applied to the outer faces of pellets38, and a further resin layer may be sprayed thereover and through itsinterstices to thus form a completed panel. Otherwise, if required, afurther layer 39 may cover the particles 38, and in this layer there maybe incorporated reinforcing in the form of shredded flakes of suitablematerial, particles of Piberglas and a proper catalyst such astriethylenetetranium, commonly known as Teta. Layer 39 will convenientlybe of the same material as layer 37. Further pellets or beads may beadded. The material is now allowed to cure to a consistency such that itmay be removed, without damage, from the mold.

With the assembly sufliciently cured, it is stripped off mold 34. If arelatively rough texture is desired, the unit may now be used. Usually,the procedure is continued by grinding and polishing the surface whichhas been in contact with the mold down to the line XX in FIG. 9. Thiswill approximate half the thickness of particles 38. These being insubstantial contact with each other, a flat, non-abrasive and impervioussurface results. This surface may be cleaned by scouring. By forming agrooved or embossed design in the mold surface, that design will beembodied in the finished article.

That article may be flexed without separation of the minute beads, whichare homogeneous with the cast sheet. The widest diameter of those beadsbeing exposed after the grinding operation, only a minimum of plastic isexposed to surface abrasion. By silvering those beads prior to includingthem in the unit, a highly reflective and desirable surface results.Thus a surface is provided that may be used to advantage in the presentstall, and will also be useful in counters, screens, wallboard, etc.

Thus, among others, the several objects of the invention as specificallyaforenoted are achieved. Obviously, numerous changes in construction andrearrangement of the parts might be resorted to, and the steps of themethod might be varied, without departing from the spirit of theinvention as defined by the claims.

I claim:

1. A shower stall including in combination a spirally curved sheetembodying resiliency such that it tends to expand, said sheet providinga vertical wall of substantially one convolution, outwardly extendingparts at the ends of said sheet and disposed in parallel and spacedrelationship to thus provide a portal, a fitting-mounting face forming apart of said sheet and extending away from the portal entrance at anangle to the axis of that entrance, a pan base for mounting said sheet,said base having an spe r53 outline substantially conforming to theoutline defined by said sheet and a surface of said pan extendingexteriorly of said sheet and providing a recess to receive and retainthe lower edge zone thereof to retain its ends against separativemovements.

2. In a stall as defined in claim 1, said sheet being relatively thinand flexible, the area defined by the normal outline of the lower edgeof the sheet being slightly difierent from that of the sheet-receivingsurface of the base, an outer wall forming a part of said base andincluding said recess and surfaces of said wall and sheet overlappingand being maintained in contact; due to the expansive tendency of saidsheet.

3. In a stall as defined in claim 1, a curbing forming a part of saidbase and extending above the face of the latter between the outwardlyextending parts of said sheet and shoulders at the ends of said curvingand the edge zones of said sheet being supported upon said shoulders.

4. A stall including in combination a spirally disposed sheet ofmaterial having its ends separated to define a portal therebetween andembodying resiliency such that those ends tend to separate, a panincluding a deck and an upwardly extending side wall defining a spaceless than the outline which said sheet tends to assume, the lower edgezone of the outer sheet face bearing against the inner face of said sidewall to restrain separation of its ends beyond a certain distance, aconnecting structure forming a part of said base and intervening theends of said sheet and said structure providing surfaces to receive andsup port the end zones of said sheet.

5. In a stall as defined in claim 4, one end zone of said sheetincluding a face extending substantially parallel to the zone at theopposite end of said sheet, said connecting structure being in the formof a sill extending upwardly from said base and of a lengthsubstantially equal to the distance between the sheet ends and parallelsurfaces forming parts of said sill to engage with the end zones of saidsheet.

6. In a stall as defined in claim 5, the parallel surfaces of said sillcomprising shoulders extending outwardly thereof, an outwardly extendingledge in the side Wall of said base and substantially in line with saidshoulders and the lower edge of said sheet resting upon said ledge andshoulders.

References Cited in the file of this patent UNITED STATES PATENTS1,215,681 Maury et al Feb. 13, 1917 1,235,091 Anderson July 31, 19172,204,929 Fairhurst June 18, 1940 2,757,385 Whittick Aug. 7, 19562,805,974 Brucker Sept. 10, 1957 2,845,379 Bey July 29, 1958 FOREIGNPATENTS 791,268 France Sept. 23, 1935

